Modular top flatwire conveyor belt systems and methods

ABSTRACT

A flatwire conveyor belt assembly includes pickets defining a leading link and a trailing link, wherein adjacent pickets are coupled with a cross-rod that extends through openings formed in the leading link and in the trailing link of adjacent pickets. Top plates are coupled to the pickets and define a conveying surface.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority under 35 U.S.C. § 119 to U.S.Provisional Patent Application No. 62/728,497 filed on Sep. 7, 2018, theentire contents of which are incorporated herein by reference.

STATEMENT CONCERNING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT

Not applicable.

TECHNICAL FIELD

The present disclosure is described in the context of flatwire conveyorbelt arrangements. More specifically, the present disclosure relates toflatwire conveyor belt systems incorporating a modular top plate engagedwith an underlying picket, which can also be configured to accommodate aguide system.

BACKGROUND

Flatwire conveyor belts, which are typically constructed from metalstrips (e.g., pickets or wickets) that are interconnected withcross-rods, continue to have applicability for a variety of conveyingapplications. The construction of flatwire conveyor belts offers anefficient strength-to-weight ratio that is relatively cost-effective tomanufacture. One disadvantage of conventional flatwire conveyor beltsrelates to the relative openness of the conveying surface, whichpresents challenges for transporting product of a size and/or formfactor that is incompatible with the relatively open conveying surface.For example, conventional construction establishes larger open areasthat can hamper effective carrying of correspondingly smaller products(e.g., products may pass partially through, become entangled with, or beunstable on the conveying surface). Conventional construction can alsoinhibit a smooth, continuous transfer of product both on to and off ofthe flatwire conveyor belt.

In addition, during use, conventional flatwire conveyor belts may have atendency, in particular applications, to shift or wander laterallyrelative to a conveying direction. The metal strip construction ofcurrent flatwire conveyor belts presents practical challenges ofeffectively and efficiently controlling and/or reducing undesirablelateral movement of the flatwire conveyor belt.

Therefore, a need exists for an improved flatwire conveyor belt systemthat maintains the conventional features and benefits, while addressingvarious deficiencies associated with the implementation and operation offlatwire conveyor belt assemblies.

SUMMARY

Some embodiments provide a flatwire conveyor belt assembly comprising aplurality of pickets, each picket defining a leading link and a trailinglink. Adjacent pickets are coupled with a cross-rod that extends throughopenings formed in the leading link and in the trailing link of adjacentpickets of the plurality of pickets. A plurality of top plates arecoupled to the plurality of pickets, wherein the plurality of top platesdefine a conveying surface.

In another embodiment, a module that is capable of use in a flatwireconveyor belt assembly comprises a picket having leading links andtrailing links, and defining a picket leading portion proximate theleading links and a picket trailing portion proximate the trailinglinks. The module also includes a top plate having a leading end and atrailing end, the top plate defining a top plate leading portionproximate the leading end and a top plate trailing portion proximate thetrailing end. The picket and the top plate interface at a leadinginterface defined by the interface of the picket leading portion and thetop plate leading portion. And, the picket and the top plate interfaceat a trailing interface defined by the interface of the picket trailingportion and the top plate trailing portion.

In a further embodiment, a top plate, that is capable of use in aflatwire conveyor belt assembly having a picket that defines leadinglink ends and trailing link ends, comprises a leading end, a top plateleading interface portion proximate the leading end, a trailing endopposite the leading end, a top plate trailing interface portionproximate the trailing end, and a transport surface that extends betweenthe leading end and the trailing end. The top plate leading interfaceportion is configured to selectively engage the leading link ends of thepicket. And, the top plate trailing interface portion is configured toselectively engage the trailing link ends of the picket.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description is to be read with reference to thefigures, in which like elements in different figures have like referencenumerals. The figures, which are not necessarily to scale, depictselected embodiments and are not intended to limit the scope ofembodiments of the invention. Given the benefit of this disclosure,skilled artisans will recognize the examples provided herein have manyuseful alternatives that fall within the scope of the invention.

FIG. 1 is a top isometric view of a portion of an example flatwireconveyor belt in accordance with one embodiment.

FIG. 2 is a bottom isometric view of the example flatwire conveyor belt.

FIG. 3 is a top isometric view of an example picket shown in FIG. 1.

FIG. 4 is a top plan view of the example picket.

FIG. 5 is a side elevation view of the example picket, with the oppositeside being a mirror image.

FIG. 6 is a bottom isometric view of an example top plate shown in FIG.1.

FIG. 7 is a bottom plan view of the example top plate.

FIG. 8 is a side elevation view of the example top plate.

FIG. 9 is a front elevation view of the example top plate.

FIG. 10 is a rear elevation view of the example top plate.

FIG. 11 is a bottom isometric, exploded view of a single example picketand a single example top plate shown in FIG. 1.

FIG. 12 is a top isometric view of a partial assembly of the examplepickets and the example top plates shown in FIG. 1.

FIG. 13 is a bottom isometric view of the partial assembly.

FIG. 14 is a top plan view of the portion of the example flatwireconveyor belt shown in FIG. 1.

FIG. 15 is a bottom plan view of the portion of the example flatwireconveyor belt.

FIG. 16 is a front elevation view of the portion of the example flatwireconveyor belt.

FIG. 17 is a rear elevation view of the portion of the example flatwireconveyor belt.

FIG. 18 is a side elevation view of the portion of the example flatwireconveyor belt, with the opposite side being a mirror image.

FIGS. 19A and 19B are bottom isometric views of an alternativeembodiment of an example flatwire conveyor belt incorporating an examplepositioning element capable of use with guide systems.

FIG. 20 is a top isometric view of another example top plate.

FIG. 21 is a bottom isometric view of the example top plate shown inFIG. 20.

FIG. 22 is a bottom plan view of a further example top plate.

FIG. 23 is a bottom isometric view of a portion of an example flatwireconveyor belt in accordance with one embodiment.

FIG. 24 is an enlarged view of the flatwire conveyor belt of FIG. 23circumscribed by arc 24-24 of FIG. 23.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including,” “comprising,” or “having” and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereofas well as additional items. Unless specified or limited otherwise, theterms “mounted,” “connected,” “supported,” and “coupled” and variationsthereof are used broadly and encompass both direct and indirectmountings, connections, supports, and couplings. Further, “connected”and “coupled” are not restricted to physical or mechanical connectionsor couplings.

The following discussion is presented to enable a person skilled in theart to make and use embodiments of the invention. Given the benefit ofthis disclosure, various modifications to the illustrated embodimentswill be readily apparent to those skilled in the art and the underlyingprinciples herein can be applied to other embodiments and applicationswithout departing from embodiments of the invention. Thus, embodimentsof the invention are not intended to be limited to embodiments shown,but are to be accorded the widest scope consistent with the principlesand features disclosed herein.

Several rows of a flatwire conveyor belt 100 in accordance with oneexample embodiment are depicted in FIGS. 1 and 2. The flatwire conveyorbelt 100 is typically an endless belt driven in a direction of travel(designated by arrow D), and constructed to address particularapplication requirements. Each row 102 includes a picket 200 thatsupports multiple modular top plates 300. Adjacent rows 102 areinterconnected by a cross-rod 104 that extends laterally (relative tothe direction of travel D) through the pickets 200 and the top plates300, generally forming a hinge connection. In use, the cross-rods 104are typically engaged by one or more sprockets driven by a motor thatrotates the sprocket(s) to engage and drive against the cross-rods 104from beneath the flatwire conveyor belt 100. In the example shown, thecross-rod 104 is metallic with ends 106 that are formed or mushroomed tolimit lateral movement (i.e., in a direction generally skewed to thedirection of travel D) of the cross-rod 104 once adjacent rows 102 areinterconnected. In alternative embodiments, other restraint mechanismscan be used to restrain the cross-rod, such as collars or clips, and thecross-rod can be constructed of non-metallic materials (e.g., plasticsor composites).

The form factor of each picket 200 allows for adjacent pickets 200 to beinterconnected and provides for interface features that allow the topplates 300 to be secured to, in some embodiments, both the picket 200and the cross-rod 104. The example picket 200 is shown and describedwith additional reference to FIGS. 3-5, and is typically manufacturedand formed from a single metallic strip having a generally uniformcross-section. While the pickets 200 are shown to define a specificpitch P (i.e., a center-to-center distance between adjacent cross-rods104) and a specific opening width W (i.e., a nominal form to allownesting and intermeshing of an adjacent picket 200), the form factor ofthe picket 200 can be adapted to address application-specificrequirements (e.g., weight of product, speed of conveyance, overallconveyor belt envelope constraints, etc.).

The example picket 200 includes edge links 202 that flank alternatingleading links 204 and trailing links 206. While the form factor of theedge links 202, leading links 204, and trailing links 206 can begenerally uniform in particular applications, the edge links 202 in theexample embodiment are narrower than the individual leading links 204and trailing links 206. Specifically, the edge links 202 define an edgeend portion 208 that is approximately half the size of a leading endportion 210 of the leading link 204 or a trailing end portion 212 of thetrailing link 206. The leading links 204 and the trailing links 206 aregenerally U-shaped (as viewed in FIG. 4) having pairs of leg portions216 formed generally orthogonally to the respective leading end portion210 and trailing end portion 212. Adjacent leg portions 216 of laterallyspaced leading links 204 and trailing links 206 are bridged by side bars214 that, in the example embodiment, are skewed relative to the pairs ofleg portions 216.

The form of the example edge links 202 varies from the leading links 204and the trailing links 206 in some respects. The edge end portion 208 ofeach edge link 202 is also generally U-shaped (as viewed in FIG. 4) anddefines an inner leg portion 218 and an outer leg portion 220 that areformed generally orthogonally to the edge end portion 208. In theexample embodiment, a side bar 214 bridges the inner leg portion 218 anda leg portion 216 of the outermost trailing link 206. The outer legportion 220 is bridged by a side bar 214 to an end bar 222 defined at alateral side of the picket 200. While the structure of the examplepicket 200 includes a certain level of uniformity and repeating patternsto aid in manufacturing of the picket 200 and construction of a flatwireconveyor belt 100, alternative embodiments may diverge from that shownto, for example, address application-specific requirements and/or goals.

The example picket 200 includes a series of features that provide forinterconnecting adjacent pickets 200 with cross-rods 104, and forinterfacing with and supporting the top plates 300. When adjacentpickets 200 have been intermeshed, a cross-rod 104 can extend throughgenerally similar openings 224 defined in the edge links 202, theleading links 204, and the trailing links 206. The openings 224 of theexample embodiment are not uniformly circular, but are somewhat oval andare positioned to extend through the corners formed between the edge endportion 208, the leading end portion 210, the trailing end portion 212,and respective leg portions 216. Similar openings 226 are formed in theedge bar 222 and are generally axially aligned with the openings 224formed in the trailing links 206. The form factor of the openings 224,226 can allow for a desired amount of slack between adjacent pickets200, generally in the direction of travel D. In addition, the formfactor of the openings 224, 226 can be tailored to accommodate a lateralcompression of the picket 200 during assembly of multiple pickets 200 toform rows of a flatwire conveyor belt 100, and to account for practicalmanufacturing tolerances and considerations associated with theinstallation and assembly of the top plates 300.

The example pickets 200 define other interface features that aretailored to engage and support top plates 300, such that when theflatwire conveyor belt 100 is traveling in a horizontal plane, the topplates 300 establish a generally continuous conveying surface 110 (e.g.,see FIG. 1). Each picket 200 defines a series of slots 228 formed in theedge end portion 208, the leading end portion 210, and the trailing endportion 212. In the example embodiment, the slots 228 are generallyrectangular with rounded corners and are positioned above a midpoint andcloser to the top of the picket 200. The edge end portions 208 areillustrated with a single slot 228 with each of the leading end portions210 and the trailing end portions 212 defining two laterally spacedslots 228. The example slots 228 can also comprise a single angled slot,one or more circular opening, protrusion, or other form factorconfigured to interact with the mating form factor provided in the topplate 300 (discussed below). The particular form factor and positioningof the slots 228 can be adapted and/or altered to accommodateapplication requirements, manufacturing constraints, or otherconsiderations (e.g., the slots 228 may be adapted to interact with amating top plate 300 to provide a biasing force urging the top plate 300into engagement with the picket 200). In the example embodiment, and asdescribed below in more detail, the slots 228 formed in the trailing endportion 212 of the trailing links 206 engage with a mating structure ofthe top plate 300 to define an example picket trailing interface portionof a trailing interface. The trailing interface establishes selectiveengagement between the picket 200 and the top plate 300 proximate thetrailing end of each.

An example leading interface establishes selective engagement betweenthe picket 200 and the top plate 300 proximate the leading end of each,and a respective cross-rod 104. The picket 200 defines openings 230 thatcan aid in positioning, assembling, and restraining the top plate 300 atan example picket leading portion of the leading interface. The openings230 are generally cylindrical, axially aligned, and extend through thevarious leg portions 216 of the edge links 202 and the leading links204. The example openings 230 can also comprise, for instance, slots,protrusions, and notches, or any other form factor configured tointeract with the mating form factor provided on the top plate 300(discussed below). Another axially aligned set of openings 230 is formedin the edge bars 222 and the trailing links 206. In one embodiment, theopenings 230 are generally uniform in form factor and are positioned ata midpoint between the upper and lower bounds of the picket 200.

Each example picket 200 also defines notches 232 that are generallyformed in the edge end portions 208 of each edge link 202, the leadingend portion 210 of the leading link 204, and the trailing end portion212 of the trailing link 206. The example notches 232 are formed in theupper portion of the edge links 202, leading links 204, and trailinglinks 206 and extend partially into respective leg portions 216 (andedge bars 222) to provide clearance for the top plate 300 when the topplate 300 is seated on top of the picket 200. In profile, as shown bestin FIG. 5, each notch extends nearly above a portion of a respective,relative opening 224, 226. The form factor and placement of the notches232 can be adapted for a particular application, such as to accommodatea particular top plate design.

The form factor of the top plates 300 allow for each to be seated atopand interface with a supporting picket 200, while also being captured toa cross-rod 104 installed to hingedly interconnect adjacent pickets 200.The example top plate 300 is shown and described with additionalreference to FIGS. 6-10. In one embodiment, the top plate 300 ismanufactured and formed from a metallic sheet having a generally uniformthickness. The top plate 300 may be manufactured from other materialsand processes; for instance, the top plate 300 can be molded from apolymeric material. In addition, while the top plates 300 are shown asuniform modular components, it is appreciated that top plates of varyingforms may be used when beneficial for a particular application.

The example top plate 300 defines a generally planar transport surface302 that includes an array of perforations 304, which can allow fordrainage and airflow through the transport surface 302. The transportsurfaces 302 of a plurality of top plates 300 can combine tocollectively define the conveying surface 110. The perforations 304 cantake on a variety of orientations, sizes, and form factors (see, forinstance, FIG. 22), or be absent (shown, for example, in FIGS. 20-21)such that the transport surface 302 is generally continuous. Inaddition, in other embodiments, the transport surface 302 can provide atextured or contoured surface that may improve frictional engagementand/or positive structural engagement between the transport surface 302and a particular product to be conveyed. The top plates 300 can furtherinclude or define application-specific structures (e.g., resilientfingers, dividers, fights, etc.).

The example top plate 300 engages the underlying picket 200 near aleading end 306 at the leading interface and near a trailing end 308 atthe trailing interface. The leading end 306 also includes structures toengage a cross-rod 104 used to pivotally interconnect adjacent rows ofpickets 200. The generally rectangular transport surface 302 of the topplate 300 is formed with downwardly extending side skirts 310, andincludes a pair of arms 312 near the leading end 306 and an arcuate tail314 near the trailing end 308. The arms 312 angle downward from thetransport surface 302 at a curved portion 316 to a lower portion 318,such that the lower portion 318 is skewed relative to the transportsurface 302. A tab 320 is formed at an orientation that generallyextends orthogonally to the lower portion 318 in a direction toward thetrailing end 308 and generally parallel with the side skirts 310. Eachlower portion 318 of the respective tab 320 includes an outer side 328that skews laterally inward toward the centerline C of the top plate 300(illustrated in FIG. 9). Each tab 320 includes an opening 322 and an ear324, which includes an arcuate upper end 326 that extends away from acenterline C of the top plate 300. As with the openings 230, the ears324 can comprise a variety of form factors (e.g., protrusions, recesses,inserts, etc.) that are configured to mate and interface with the formfactor defined by the picket leading interface portion (e.g., theexample openings 230). The openings 322 are somewhat elongated and aresized and positioned to accommodate the cross-rod 104 during use;therefore, in the example embodiment, the top plates 300 are engagedwith the pickets 200 prior to inserting the cross-rods 104 tointerconnect adjacent rows of top plates 300 and supporting pickets 200.

The tail 314 near the trailing end 308 curves downward and away from thetransport surface 302, ultimately curving back toward the leading end306 of the top plate 300 at a trailing edge 330 to define generallyhorizontal lip 332. As best illustrated in FIG. 7, the example tail 314includes sides 334 that skew inward towards the centerline C of the topplate 300. In the example top plate 300, a pair of laterally spaced tabs336 extend from the lip 332 toward the leading end 306. Each tab 336slightly tappers toward a tip 338, and the tabs 336 comprise a portionof the example top plate trailing interface portion of the trailinginterface between the picket 200 and the top plate 300. The tabs 336 cantake on a variety of form factors (e.g., openings, slots, grooves,protrusions, nibs, inserts, etc.), provided the top plate trailinginterface portion and the picket trailing interface portion are adaptedto interact at the trailing interface between the picket 200 and the topplate 300 to interface the top plate 300 and the picket 200.

With specific reference to FIG. 8, the form factor of the top plate 300includes features that generally maintain a desired spacing andorientation between adjacent top plates 300 during use. The curvedportion 316 defines an arcuate segment 317 that has a leading radius ofcurvature LR extending from a leading pivot axis LP, and the tail 314defines another accurate segment 315 that has a trialing radius ofcurvature TR extending from a trailing pivot axis TP. The curvature ofthese segments 315, 317 (relative to the leading and trailing pivot axesgenerally defined by the orientation of the leading and trailingcross-rods 104) maintains a nearly constant spacing between adjacent topplates 300 as they traverse and pivot about the leading pivot axes LPand the trailing pivot axes TP. In addition, these features maintain aconsistent and relatively smooth transition between adjacent top plates300.

The example interface and engagement between the picket 200 and topplate 300 is described with additional reference to FIGS. 11-13. Theexample picket 200 and the example top plate 300 are configured tointerface at a leading interface and at a trailing interface (annotatedin FIG. 11 as LI and TI, respectively). Specifically, the leadinginterface includes a picket leading portion and a top plate leadingportion that are both adapted to establish cooperating form factors thatmate the picket 200 and the top plate 300 near leading ends. As shown inthe example configuration, the picket 200 includes an example picketleading portion defining openings 230 that establish a form factoradapted to interface with an example top plate leading portion of thetop plate 300 defining ears 324. In addition or alternatively, theexample leading interface can include the cooperation between theopenings 224 of the picket 200, the openings 322 in the top plate 300,and the assembly of the cross-rod 104 through the openings 224, 322.Similarly, the trailing interface includes a picket trailing portion anda top plate trailing portion that are both adapted to establishcooperating form factors that mate the picket 200 and the top plate 300near trailing ends. As shown in the example configuration, the picket200 includes an example picket trailing portion defining slots 228 thatestablish a form factor adapted to interface with an example top platetrailing portion of the top plate 300 defining tabs 336. Given thebenefit of this disclosure, one of ordinary skill in the art willappreciate the various structures and form factors that can be employedto implement the interface concepts that can inhibit separation of topplates from pickets.

To mate the example top plate 300 with the example picket 200, the topplate 300 is generally aligned as shown in FIG. 11 (as annotated byengagement lines). The tabs 336 on the trailing end 308 of the top plate300 are aligned for insertion into the slots 228 formed in the trailingend portions 212 of the trailing link 206. The tapered form factor ofthe tabs 336 can be configured to securely engage a receiving formfactor defined by the structure of the slots 228. Turning to the leadingend 306 of the top plate 300, the opening 322 in one tab 320 isgenerally aligned with the opening 224 formed near the leg portion 216of the edge link 202, and the other opening 322 of the other tab 320 isgenerally aligned with the opening 224 formed near the leg portion 216of the leading link 204. Similarly, the ear 324 of one tab 320 isgenerally aligned with the opening 230 formed in the leg portion 216 ofthe edge link 202, and the other ear 324 of the other tab 320 isgenerally aligned with the opening 230 formed in the leg portion 216 ofthe leading link 204. The contour of the ears 324 and the respectiveupper ends 326 are inserted by slight elastic deformation of, forinstance, one or more of the picket 200, the ear 324, and the tab 320.Once engaged, the upper ends 326 of the ears 324 interfere with theboundary of the opening 230 to inhibit unintentional removal of the topplate 300, and can abate noise caused by excess relative movement of thetop plate 300. In addition, the interaction between and relativeplacement of the ears 324 and the corresponding openings 230 establishpositioning features that aid assembly of the top plates 300 to thepickets 200 by, for example, aligning the openings 230 in the picket 200with the openings 322 in the top plate 300 (discussed below) to readilyreceive the cross-rod 104.

When the top plate 300 of FIG. 11 is installed, the top plate 300extends between and generally covers the edge link 202, the laterallyadjacent trailing link 206, and approximately half of the laterallyadjacent leading link 204 (best illustrated in FIGS. 12 and 13). Withspecific reference to FIGS. 12 and 13, another top plate 300 can besimilarly assembled by again aligning the interconnecting interfacefeatures of the picket 200 and the additional top plate 300.

With the desired top plates 300 secured to the appropriate pickets 200,the cross-rods 104 can be aligned with the respective openings 224, 226in the edge links 204, leading links 206, and trailing links 208 of thepickets 200, and openings 322 in the tabs 320 of the top plates 300. Inother embodiments, the pickets 200 and top plates 300 can be modifiedsuch that the top plate 300 is secured to the pickets 200 by tabs 336 onthe trailing end 308 and by similar tabs on the leading end 306. Forinstance, tabs on the leading end 306 may extend from the lower portion318 of the top plate 300 and extend into the slots 228 formed in theedge link 202 and the leading links 204.

A portion of the flatwire conveyor belt 100 illustrating four rows 102is further shown in FIGS. 14-18, and various additional features of thepickets 200 and the top plates 300 are illustrated. In one embodiment,the top plates 300 are sized to provide a lateral space or gap 108between laterally adjacent top plates 300. This provides, for instance,space to accommodate lateral compression of the underlying pickets 200that can occur during assembly of the flatwire conveyor belt 100. Thegap 108, however, can be sized to reduce the potential for productsbeing conveyed to undesirably interact with the gap 108. Where arelatively smooth, continuous conveying surface 110 is desired, thenotches 232 formed in the edge end portions 208 of each edge link 202,the leading end portion 210 of the leading link 204, and the trailingend portion 212 of the trailing link 206 can accommodate a respectivetop plate 300, such that the top plate 300 is seated in preferredorientation relative to other top plates 300 and may be positionedgenerally directly on the picket 200.

In addition, several contours and form factors of the pickets 200 andthe top plates 300 enhance hinging of the adjacent rows 102. Forinstance, the contours of the arms 312 at the leading end 306 and thetail 314 at the trailing end 308 can be configured to establish desiredclearance for uninhibited rotation within a practical range of operationof the flatwire conveyor belt 100.

In the example embodiment, each row 102 is generally identical andcomprised of pickets 200 and top plates 300 of substantially similarform factors, respectively. In addition, the picket 200 and the topplate 300 include various contours provided to enhance manufacturabilityfrom strip/sheet material using, for instance, die cutting, stamping,and press forming processes. Depending on the form factor and envelopeconstraints for a particular flatwire conveyor belt application, thespacing and construction of the picket and top plate can be adaptedaccordingly. For example, top plates of varying form factor can beprovide to establish a brick-lay pattern having offset top plateplacement between adjacent rows, such that successive rows do notcombine to establish continuous gaps or contours. In one example, acombination of top plates of discrete lateral dimensions (e.g., 6 inchesin lateral width and 3 inches in lateral width) can be configured toestablish a brick-lay pattern.

An alternative embodiment of an example portion of flatwire conveyorbelt 400 is illustrated in FIGS. 19A and 19B. While many similarities tothe flatwire conveyor belt 100 are present, a difference exists in thata picket 402 has been modified to accommodate and restrain a portion ofa guide system. For example, the guide system, such as the Positracksystem employed by Rexnord Corporation of Milwaukee, Wis., can include atrack or rail (not shown). The flatwire conveyor belt 400 includes amating positioning element 404 that is configured to interact with thetrack or rail during operation of the flatwire conveyor belt 400. Theexample positioning element 404 includes various surfaces, such aslateral sides 406, which can be configured to ride along or engage withportions of the track or rail to direct, limit, or at least partiallyrestrain undesired movement of the flatwire conveyor belt 400.

With additional reference to FIGS. 3 and 5, the form factor of theexample picket 402 is similar to picket 200. Picket 402 includes aseries of openings 215 that are formed through select ones of the sidebars 214. While the axis of each opening 215 is generally aligned, inone embodiment, the openings 215 formed in the respective side bar 214of the end links 202 may be positioned slightly above the openings 215formed in the remaining side bars 214 (shown best in FIG. 5). Withspecific reference to FIGS. 19A and 19B, the picket 402 differs in thatat least side bar 408 does not include any opening (i.e., similar toopenings 215). Therefore, the example positioning element 404 can beseated between trailing links 206 and a guide rod 410, which is sizedaccordingly, can be inserted into the openings 215, through cylindricalchannel or openings 411 in or through the positioning element 404, andgenerally abutted against side bar 408. This construction effectivelycaptures the positioning element 404 with the picket 402. To inhibit theguide rod 410 from undesirable removal, a rivet 412 (or other structure,such as a plug, a clip, etc.) can be used to block at least a portion ofthe outermost opening 215 formed in the edge link 202.

An alternative top plate 500 is illustrated in FIGS. 20 and 21. Whilethe top plate 500 is similar to the top plate 300, various differencesare shown. The top plate 500 includes leading arms 502, 504 that extendfrom a main body 506 in a leading direction, and a single trailing tail508 that extends from the main body 506 in a trailing direction. Themain body 506 includes a generally continuous, planar transport surface507. Similar to the top plate 300, the tail 508 curves downward from themain body 506 and terminates in a pair of laterally spaced tabs 510. Thetabs 510 are configured to interface with mating slots formed in asupporting picket (e.g., slots 228 formed in the trailing end portion212 of the picket 200 shown in FIG. 11). The tail 508 further includes aseries of openings 512 formed along a trailing end 514.

The leading end of the top plate 500 differs somewhat from the top plate300. Each arm 502, 504 includes a curved portion 516 that extends fromthe main body 506 and downward to terminate in a leading tab 518. Theleading tabs 518 are generally rectangular in form factor and extendfrom distal ends of the arms 502, 504 toward the tail 508. The leadingtabs 518 are configured to engage mating slots formed in the leading endportion of a picket, such as the slots 228 formed in the leading endportion 210 of the picket 200 (show in FIG. 3). The arms 502, 504 alsoinclude a series of openings 520 formed along a leading end 522.

The alternative top plate 500 engages the underlying picket (e.g.,picket 200) at a leading interface and at a trailing interface. Inparticular, the tabs 510 of the tail 508 are engaged with respectiveslots 228 formed in the trailing end portion 212 of the picket 200, andthe leading tabs 518 are engaged with respective slots 228 formed in theleading end portion 210 of the picket 200. The top plate 500 and/or thepicket (e.g., picket 200) may be elastically deformed or flexed to allowthe top plate 500 to be aligned and releasably engaged with theunderlying picket 200. Given the benefit of this disclosure, one skilledin the art will appreciate the various interface form factors availableto implement the fundamental concepts.

Another alternative top plate 600 is illustrated in FIG. 22. The topplate 600 defines a main body 602 with an array of perforations 604 thatextend through the main body 602 between a transport surface and anunderside. Each perforation 604 is generally cylindrical and the arrayof perforations 604 is generally mirrored about line L. In otherembodiments, perforations may be non-uniform, both in individual formfactor and/or in relative position on the top plate 600. One skilled inthe art will understand the various alternatives that fall within thepurview of the disclosed concepts.

FIG. 23 illustrates another flatwire conveyor belt 700 in accordancewith one example embodiment. The flatwire conveyor belt 700 is similarto the flatwire conveyor belt 100 described above and is typically anendless belt driven in a direction of travel (designated by arrow D),and constructed to address particular application requirements. Each row702 includes a picket 800 that supports multiple modular top plates 900.Adjacent rows 702 are interconnected by a first set of cross-rods 704that extends laterally (relative to the direction of travel D) throughthe pickets 800, generally forming a hinge connection. A second set ofcross-rods 712 also extends laterally through the pickets 800. As shown,the first set of cross-rods 704 and the second set of cross-rods 712 areprovided in an alternating pattern; however, fewer of the second set ofcross-rods 712 can be provided depending on the application-specificrequirements.

In use, the first set of cross-rods 704 is typically engaged by one ormore sprockets driven by a motor that rotates the sprocket(s) to engageand drive against the first set of cross-rods 704 from beneath theflatwire conveyor belt 700. The second set of cross-rods 712 extendsthrough and supports rollers 714. Each of the rollers 714 can rotateabout a respective cross-rod of the second set of cross-rods 712 freelyand independently from each other, the pickets 800, and the modular topplates 900. In other forms, some or all of the rollers 714 may berotatably secured to the cross-rods 712 such that the rollers 714 andcross-rods 712 rotate in unison. It is contemplated that there may begreater or fewer rollers 714 per picket 800 (or per flatwire conveyorbelt 700) than shown in FIG. 23, as adjustments can be made depending onthe application-specific requirements (e.g., load-carrying capacityrequirements). The example rollers 714 are generally cylindrical with acentral axial opening though which the cross-rods 712 extend. Inalternative embodiments, the rollers 714 may take other form factors,such as tapered, arcuate, convex, concave, and the like. The rollers 714can be constructed of, for instance, a variety of plastic and/ormetallic materials, and may include an internal bushing, bearing, andthe like within the central axial opening to influence the relativeengagement with the cross-rods 712 (e.g., reduce sliding friction).

In the example shown, both the first and second sets of cross-rods 704,712 are metallic with ends 706, 716 that are formed or mushroomed tolimit lateral movement (i.e., in a direction generally skewed to thedirection of travel D) of the cross-rods 704, 712 once adjacent rows 702are interconnected. In alternative embodiments, other restraintmechanisms can be used to restrain the cross-rods, such as collars orclips, and the cross-rods can be constructed of non-metallic materials(e.g., plastics or composites). One alternative example construction isshown in FIG. 23 in which the cross-rod 712 takes the form of an axle802 that is captured in a row 804. Specifically, a modified picket 806of the row 804 differs as the outermost side bar 808 does not include anopening aligned with the assembled axle 802. Thus, the axle 802 can beinserted through generally aligned openings 810 in the picket 806 untilthe axle 802 abuts the outermost side bar 808. The opening 810 formed inthe opposite outermost side bar 812 can be blocked by a rivet 814 (orother structure, such as a plug, a clip, etc.) to inhibit the axle 802from excessive lateral movement. In this embodiment, the axle 802 isgenerally free-floating, such that the axle 802 is able to rotate andshift laterally, while being ultimately restrained by the outermost sidebar 808, the openings 810, and the rivet 814.

As shown in FIG. 24, the example second set of cross-rods 712 (or axle802) can be spaced from the modular top plates 900 so that the secondset of cross-rods 712 is lower in the pickets 800 in relation to thefirst set of cross-rods 706. As shown, a first dimension A between thecenter axis of the second set of cross-rods 712 and the top surface ofthe flatwire conveyor belt 700 is greater than a second dimension Bbetween the center axis of the second set of cross-rods 712 and thebottom surface of the flatwire conveyor belt 700. This defines a gap 718between the top of the rollers 714 and the modular top plates 900,thereby allowing the rollers 714 to extend below the pickets 800 but notinterfere with the modular top plates 900. The relationship between thefirst dimension A and the second dimension B is generally constrained bythe first dimension A avoiding interference between the rollers 714 andthe modular top plates 900, and the second dimension B accommodatingsufficient material of the picket 800 to achieve the particularapplication requirements (e.g., fatigue strength, load-carryingcapacity, etc.). In one particular embodiment, the rollers 714 can beconfigured to extend beyond the bottom surface approximately 1/16″ to⅛″, with a correspondingly sized gap 718.

It will be appreciated by those skilled in the art that while theinvention has been described above in connection with particularembodiments and examples, the invention is not necessarily so limited,and that numerous other embodiments, examples, uses, modifications, anddepartures from the embodiments, examples, and uses are intended to beencompassed by the claims attached hereto. For example, the spacing,size, gauge, form-factor, and other features may vary based onapplication-specific requirements (e.g., product to be conveyed,environmental factors, speed of conveyance, operational envelopelimitations, etc.). In addition, while the embodiments have beendescribed in context of a metallic construction, it is contemplated thatother materials (e.g., polymers) or composite constructions (e.g., ametallic base with a plastic overmold) are possible. The interfaceconcept disclosed establishes a flatwire conveyor belt that maintainsthe strength of the assembly, as the conveyor belt is placed in tensionduring use, and further supports top plates in such a manner as to allowthe top plates to be produced from relatively thin material, therebyreducing the net conveyor belt weight. Other types of conveyor belts mayalso benefit from the incorporation of aspects of the invention. Theentire disclosure of each patent and publication cited herein isincorporated by reference, as if each such patent or publication wereindividually incorporated by reference herein.

Various features and advantages of the invention are set forth in thefollowing claims.

The invention claimed is:
 1. A flatwire conveyor belt assemblycomprising: a plurality of pickets, each picket defining a leading linkand a trailing link, wherein adjacent pickets are coupled with across-rod that extends through openings formed in the leading link andin the trailing link of adjacent pickets of the plurality of pickets;and a plurality of top plates coupled to the plurality of pickets,wherein the plurality of top plates define a conveying surface; andwherein each of the plurality of top plates defines a leading end and atrailing end, and an opening formed in the leading end of the top plate;wherein at least one of the leading end and the trailing end of the topplate is interfaced with one of the plurality of pickets; and whereinthe cross-rod extends through the opening formed in the leading end ofthe top plate to interface the leading end of the top plate and theleading link of the picket.
 2. The flatwire conveyor belt assembly ofclaim 1, further comprising: a slot formed in the trailing link of thepicket; a tab formed in the trailing end of the top plate; and whereinthe tab engages the slot to interface the trailing end of the top plateand the trailing link of the picket.
 3. The flatwire conveyor beltassembly of claim 1, further comprising: another opening formed in theleading link of the picket; a tab formed in the leading end of the topplate; and wherein the tab engages the another opening to interface theleading end of the top plate and the leading link of the picket.
 4. Theflatwire conveyor belt assembly of claim 3, wherein: the tab furthercomprises an ear; and the ear is seated in the another opening formed inthe leading link to inhibit separation of the top plate and the picket.5. The flatwire conveyor belt assembly of claim 1, further comprising anarray of perforations formed through the top plate.
 6. A flatwireconveyor belt assembly comprising: a plurality of pickets, each picketdefining a leading link and a trailing link, wherein adjacent picketsare coupled with a cross-rod of a first set of cross-rods that extendsthrough openings formed in the leading link and in the trailing link ofadjacent pickets of the plurality of pickets; a plurality of top platescoupled to the plurality of pickets, wherein the plurality of top platesdefine a conveying surface; a second-set of cross-rods extending throughthe plurality of pickets; and a roller received on each of thesecond-set of cross-rods; and wherein the second set of cross-rodscomprises axles that are spaced farther from the plurality of top platesthan the first set of cross-rods.
 7. A module capable of use in aflatwire conveyor belt assembly, the module comprising: a picket havingleading links and trailing links, the picket defining a picket leadingportion proximate the leading links and a picket trailing portionproximate the trailing links; a top plate having a leading end and atrailing end, the top plate defining a top plate leading portionproximate the leading end and a top plate trailing portion proximate thetrailing end; wherein the picket and the top plate interface at aleading interface defined by the interface of the picket leading portionand the top plate leading portion; wherein the picket and the top plateinterface at a trailing interface defined by the interface of the pickettrailing portion and the top plate trailing portion; wherein the picketleading portion comprises a picket opening; wherein the top plateleading portion comprises a top plate opening; and wherein the picketopening and the top plate opening are configured to interface when thetop plate is positioned adjacent to the picket, such that a cross-rodcan extend into the picket opening and the top plate opening to inhibitseparation of the top plate and the picket.
 8. The module of claim 7,wherein: the picket leading portion comprises another opening; the topplate leading portion comprises an ear; and the another opening and theear are configured to interface when the top plate is positioned atopthe picket to inhibit separation of the top plate and the picket.
 9. Themodule of claim 7 further comprising: a second cross-rod extendingthrough the picket; and a roller received on the second cross-rod. 10.The module of claim 7, wherein: the picket trailing portion comprises aslot; the top plate trailing portion comprises a tab; and the slot andthe tab are configured to interface when the top plate is positionedatop the picket.
 11. A top plate capable of use in a flatwire conveyorbelt assembly having a picket that defines leading link ends andtrailing link ends, the top plate comprising: a leading end; a top plateleading interface portion proximate the leading end; a trailing endopposite the leading end; a top plate trailing interface portionproximate the trailing end; and a transport surface that extends betweenthe leading end and the trailing end; wherein the top plate leadinginterface portion is configured to selectively engage the leading linkends of the picket; wherein the top plate trailing interface portion isconfigured to selectively engage the trailing link ends of the picket;and wherein the top plate leading interface portion comprises at leastone opening formed in a tab that is configured to receive a cross-rodfor interconnecting adjacent pickets.
 12. The top plate of claim 11,wherein the top plate leading interface portion comprises at least oneear that extends from the top plate.
 13. The top plate of claim 12,wherein the at least one ear extends from the tab formed proximate theleading end of the top plate.
 14. The top plate of claim 11, wherein thetop plate trailing interface portion comprises at least one tab.
 15. Thetop plate of claim 14, wherein the at least one tab extends parallel tothe transport surface.
 16. A flatwire conveyor belt system comprising: apicket with a first set of openings; a plurality of top platesconfigured to be removably attached to the picket, each top plate havingan opening alignable with the first set of openings of the picket; and across-rod received through the first set of openings of the picket andthe openings of the top plates.
 17. The flatwire conveyor belt system ofclaim 16, wherein: each top plate has a trailing end with a tab; thepicket has a plurality of trailing end portions each with a slot; andthe tabs of the top plates are removably receivable within the slots ofthe trailing end portions.
 18. The flatwire conveyor belt system ofclaim 16, wherein: the picket has a second set of openings; each topplate has an ear approximate the opening of the top plate; and the earsof the top plates are removably receivable within the second set ofopenings of the picket.
 19. A flatwire conveyor belt assemblycomprising: at least one picket having: a leading link including: a pairof leading leg portions; a leading end portion connecting the pair ofleading leg portions; and a leading link interface; and a trailing linkincluding: a pair of trailing leg portions; a trailing end portionconnecting the pair of trailing leg portions; and a trailing linkinterface; and at least one top plate having: a leading top plateinterface; and a trailing top plate interface; and wherein the leadinglink interface and the leading top plate interface are configured toestablish a leading assembly coupling between the at least one top plateand the at least one picket; wherein the trailing link interface and thetrialing top plate interface are configured to establish a trailingassembly coupling between the at least one top plate and the at leastone picket; and wherein at least one of the leading assembly couplingand the trailing assembly coupling is configured to establish anelastically releasable coupling between the at least one top plate andthe at least one picket.
 20. The flatwire conveyor belt assembly ofclaim 19, wherein: the at least one picket further includes a sidebarextending between one leading leg portion of the pair of leading legportions and one trailing leg portion of the pair of trailing legportions to bridge the leading link and the trailing link; the leadinglink interface is integral with the leading end portion; and thetrailing link interface is integral with the trailing end portion. 21.The flatwire conveyor belt assembly of claim 19, wherein the at leastone top plate is configured to be elastically flexible to establish theelastically releasable coupling between the at least one top plate andthe at least one picket.
 22. The flatwire conveyor belt assembly ofclaim 19, wherein: the leading link interface is integral with theleading end portion and comprises a leading slot; the trailing linkinterface is integral with the trailing end portion and comprises atrailing slot; the leading top plate interface comprises a leading armterminating in a leading tab configured to couple with the leading slot;and the trailing top plate interface comprises a trailing tailterminating in a trailing tab configured to couple with the trailingslot.
 23. The flatwire conveyor belt assembly of claim 19, wherein: theleading link interface is integral with one of the pair of leading legportions and comprises a leading opening; the trailing link interface isintegral with the trailing end portion and comprises a trailing slot;the leading top plate interface comprises an ear integral with a tabconfigured to mate with the leading opening; and the trailing top plateinterface comprises a trailing tail terminating in a trailing tabconfigured to mate with the trailing slot.
 24. The flatwire conveyorbelt assembly of claim 19, wherein: the leading link interface definesat least one of a leading link opening, a leading link slot, and aleading link tab; the trailing link interface defines at least one of atrailing link opening, a trailing link slot, and a trailing link tab;the leading top plate interface defines at least one of a leading topopening, a leading top slot, and a leading top tab; and the trailing topplate interface defines at least one of a trailing top opening, atrailing top slot, and a trailing top tab.
 25. The flatwire conveyorbelt assembly of claim 19, wherein: the at least one top plate includesa main body defining a transport surface; the leading top plateinterface includes leading arms extending from the main body in aleading direction, the leading arms curve away from the transportsurface and terminate in leading tabs extending toward the trailingtail; the trailing top plate interface includes a trailing tailextending form the main body in a trailing direction that is oppositethe leading direction, the trailing tail curves away from the transportsurface and terminates in a trailing tab extending toward the leadingarms; the leading link interface includes a pair of slots configured toreceive the leading tabs; and the trailing link interface includes aslot configured to receive the trailing tab.